Conversion of hydrocarbon oils into gasoline



May 30, 1939. R. F. RUTHRUFF CONVERSION OF HYDROCARBON OILS INTO GASOLINE Original Filed Dec. 17, 1934 2 Sheets-Sheet l Ox S8.

INVENTOR m Tn @m ATTORNEY May 30, 1939- R. F. RUTHRur-'F CONVERSION OF HYDROCARBON OILS INTO GASOLINE 2 sheets-sheet 2 Original Filed Dec. 17, 1954 INVENTOR Robert E/Q/Z ATTORNEY CU S5 Lk @Q A QQ om Q NQ @NN NN L@ @mgl @SPG OLR uk mk Patented May 30, 1939 UNITED STATES PATENT OFFICE Robert F. RuthruIL'Hammond, Ind., assigner to Standard Oil Company,` Chicago, Ill., a corporation ol' Indiana Application December 17, 1934, Serial No.

Renewed August 11, 1938 13 Claims.

This invention relates to an improvement in the conversion of heavy oils into gasoline. More specifically, it relates to an improved combination of an oil cracking unit; preferably a complete unit of the type which utilizes crude oil as charging stock and eliminates gasoline and heavy fuel oil as its principal liquid products, together with one or two gas polymerization units functioning to convert the gas from the cracking unit to additional liquid products.

Briefly described, my improved process is characterized by the fact that I take the gas streams from the cracking section of the oil cracking unit and subject them to polymerization, returning the' liquid products from the polymerization section to the cracking system. The gas streams from the cracking section, preferably after elimination of methane and hydrogen, are preferably separated into two fractions, one of which contains ethylene as a predominating unsaturated constituent, the other fraction containing propy- Iene-butylene as its predominating unsaturated constituents. I preferably subject the latter fraction to catalytic polymerization at relatively low temperatures and pressures and the former fraction to non-catalytic polymerization at relatively high temperatures and pressures. I prefer to combine the total liquid products, i. e., gasoline and heavier, from both polymerization systems and return them to the cracking system whereby polymerization products heavier than gasoline are subjected to cracking and polymerized products of gasoline boiling range are eliminated from the system in admixture with the cracked gasoline.

Unconverted gases from the polymerization section or sections may be eliminated from the system or may be recovered and subjected to a high temperature gas cracking step in order to generate additional unsaturated gases which may be returned to the polymerization section or scctions. In case I operate such a gas cracking step, the unconverted gases from the polymerization section or sections will ordinarily be fractionated and recovered in conjunction with the saturated gases from the crude oil which are recovered by fractionation of the light virgin gasoline from the crude oil.

By means of my improved combination process considerable increases in the yield and quality of the total gasoline obtained from the crude oil are realized. Since ethylene is not readily converted by improved catalysts which rapidly and smoothly convert higher gaseous oleins to liquids, my combination of high pressure polymerization and catalytic polymerization with the oil cracking system leads to optimum results. Furthermore, bythe catalytic polymerization step I may eliminate all, or essentially all, of butylene and iso-butylene from the cracked gasoline produced by the system. Since butylene and isobutylene have a higher vapor pressure than butane and iso-butane this permits increasing the butane content of the gasoline whereby its volatility and starting qualities may be improved without encountering diiilculties from excess uncontrolled volatility as reflected in practice by tendency to vapor-lock automotive engines. The mixed polymerized and cracked gasoline produced by my system also usually has improved anti-knock value as compared to ordinary cracked gasoline. I also clay treat the vapors from the gasoline from the cracking unit and I have found that advantages in operation are obtained by clay treating the cracked gasoline vapors in admixture with vapors of polymerized gasoline.

The operation of my process will be understood from the following detailed description and reference to the drawings attached hereto and which form part of this specification, Figure 1 and Figure 2 taken together representing a diagrammatic elevational view of apparatus suitable for carrying out my process, Figure 1 representing -the oil cracking section of the system while Figure 2 represents the gas polymerizing and gas cracking sections of the system.

The oil cracking system of my process may be varied in accordance with the type of crude handled and the other requirements of the particular situation. An arrangement which I ordinarily prefer is as follows:

Referring rst to Figure 1, cold crude oil is introduced through line I0 and preferably is preheated by passing through reflux exchanger or coils II in the upper section I2 of the crude flash tower, then through reiiux exchanger coils I3 in bubble tower I 4, then through line I5 and heat exchanger I6 wherein additional heat is picked up from the bottoms from bubble tower I4, then through line Il into upper section I2 of the crude flash tower. In this section I2 of the tower light virgin naphtha plus all of the gases present in the crude are flashed off and are removed through line I 1a. The unvaporized material is withdrawn from the bottom of section I2 through line I8, and passes to a low point in the middle section I9 of the flash tower, where vapors of virgin heavy naphtha are ashed off and are withdrawn from the upper part of section I9 through line 20. The residual unvaporized portion of the crude is withdrawn from the lower part of section I9 through line 2I and introduced by pump 22 into an elevated point in evaporator tower 23. Vapors of heavy gas oil flashed off from the final cracked fuel oil in the lower section 24 of the flash tower rise through line 25 into the middle section I9, thus providing additional heat for stripping heavy naphtha from the crude oil in section I9 and being themselves condensed and wlthdrawnthrough line 2|.

In the evaporator 23 the gas oil and similar constituents of the crude oil are vaporized and the heavy residual portion of the crude is withdrawn from trap-out tray 26 by line 21 and goes to the so-called viscosity breaker accumulator drum 28 from which it is pumped by pump 29 through viscosity breaker furnace 30 wherein it is heated totemperatures of 850 to 925 F. while under pressures of 100 to 750 lbs. per sq. in. Appreciable conversion of heavy oils to gasoline takes place in the viscosity breaker furnace, ordinarily about 5 to 15% being converted to gasoline. Another important function of this furnace, however, is to viscosity break the heavy residue, i. e., to reduce its viscosity by moderate cracking. All products from the viscosity through line 3| back to evaporator 23 below trap-out tray 26.

Vapors leaving the evaporator through line 32 include all gasoline formed in the cracking system, together with all gas oil, and are introduced through line 32 into the middle section of bubble tower I4. Unconverted gas oil from the cracking furnaces, together with fresh gas oil distilled in evaporator 23 from the crude residuum charged to the evaporator 23 through line 2|, are condensed in bubble tower I4 and are withdrawn from the tower through line 33 and preferably through heat exchanger I6 to gas oil accumulator drum 34 from which the gas oil is pumped by pump 35, through line 36, to the gas oil furnace 31. In furnace 31 the gas oil is subjected to cracking under relatively severe conditions, i. e., temperatures of 9001050 F. while under pressure of 100-750 lbs. per sq. in. or more, the rate of flow being such that a conversion of about 15% to 40% of the gas oil to gasoline is realized in one passage through the furnace. Products from the gas oil furnace 31 are withdrawn through line 38 and ordinarily are passed through valve 39 to unheated reaction drum 40 wherein additional time for the cracking reactions is afforded. Products leave the reaction drum through valve 4I and line 42, being introduced into a low point in evaporator 23 below trap-out tray 26. I may, however, eliminate reaction drum 40 by closing valves 39 and 4i and opening valves 43 and 44 in by-pass 45.

The heavy virgin naphtha vaporized from the crude oil in section I9 of the flash tower and withdrawn through line 20, is condensed by cooler 46 and passes to naphtha accumulator drum 41 from which it is withdrawn and pumped by pump 48 through line 48a to naphtha reformer furnace 49 wherein it is subjected to cracking at temperatures of 950 to 1100.o F, while lunder pressures of 200 to 1500 lbs. per sq. in. to the end that the principal products are gasoline and gas and the antiknock value of the virgin naphtha is materially increased. The products are withdrawn from furnace 49 through line 50 and introduced into a low point of evaporator 23 below trap-out tray 26.

of the heavy residue breaker furnace 30 pass the lower section of the v All of the gasoline formed in the three cracking furnaces and most of the gas oil are vaporized and pass out of the evaporator through line 32 to the bubble tower I4 but some of the heavy gas oil may be condensed in the evaporator 23 and trapped out by tray 26 and charged to the viscosity breaker furnace 30. The unvaporized cracked residuum'or tar plus some unvaporized heavy gas oil are withdrawn from the bottom of evaporator 23 through line 5I and valve 52 and pass to the bottom section 24 of the fuel oil flash tower which operates substantially at atmospheric pressure. In this section all remaining gas oil is flash distilled from the cracked products as previously described, and heavy residual fuel oil is Withdrawn from the system through line 53.

Cracked gasoline vapors and gas are removed from the top of bubble tower I4 through line 54 and pass preferably through valve 55 into clay towers 56 and 51 wherein undesirable gum forming constituents in the gasoline are polymerized and removed in liquid form through 'valves 58 and 59, these liquid polymers being returned by pump 60 in line 6I to the evaporator 23 or to some other convenient point in the cracking system whereby these liquid polymers are recracked to gasoline. The clay treating towers may be eliminated from the system by closing inlet valve 55 and valve 62 in exit line 63 and opening valves 64 and 65, in by-pass 66.

The gasoline vapors in line 63 pass through condenser and cooler 61 which may be a water cooled condenser pure and simple or may combine cooling by heat interchange (with cooler streams in the cracking system) followed by water cooling. The condensed cracked products, together with any uncondensed gases, pass from condenser 61 through line 63-to separator 68 without any reduction in pressure, uncondensed gases being withdrawn from separator 68 through oiftake 69, said gases consisting predominatingly of hydrogen and methane. The liquid condensates are removed from separator 68 and passed by pump 10 through line 1I to stabilizer 12 which is provided with suitable bottom heating means 13 and top cooling means 14, whereby the liquid condensate is fractionated and finished stabilized end point gasoline may be withdrawn through line 15 from the bottom of stabilizer 12, while undesired light constituents,

v comprising ethylene, propylene and in some instances butylene together with the corresponding saturated hydrocarbons, are Withdrawn from the top of stabilizer 12 through line 16, the pressure and temperature in stabilizer 12 being suitably regulated to this end. Although I have stated that finished stabilized gasoline is withdrawn from separator 12, such gasoline ordinarily preferably containing a considerable proportion of the total butane and butylene present in the cracked products, for reasons which will later appear I may also operate stabilizer 12 so as to send most of the butane and butylene overhead through line 16, in which case the gasoline n withdrawn through line 15 Will be deficient in volatile light ends.

The overhead vapors leaving stabilizer 12 through line 16 are ordinarily introduced through valve 11 into fractionator 18 which is provided with suitable bottom heating means 19 and top cooling means whereby a fraction comprising predominatingly ethane and ethylene is removed in a vaporous or gaseous form from the top thereof through line 8| while a condensate conslsting predominatingly of propane and propylene, together with any butane and butylene present, is withdrawn from the bottom thereof through line 32.

In the operation of the aforedescribed cracking and fractionation system, I will ordinarily maintain a pressure of 100 to '750 lbs, per sq. in. on reaction drum 48 while evaporator 23 and bubble tower |4 will ordinarily be operated under about 200 lbs. per sq. in. pressure, which pressure will ordinarily be continued without reduction through the clay towers 58 and 51 and the separator 68. Stabilizer 12 and fractionator 18 will ordinarily be operated at pressures of approximately 100-350 lbs. per sq. in. and condensing and pumping means not shown may be introduced in line 16 if it is desired to operate fractionator 18 at a higher pressure than stabilizer 12.

The condensed liquid materials removed from fractionator 18 through line 82, comprising propane and propylene, and containing in some cases substantial proportions of butylene and butane, are passed by pump 83 to the catalytic polymerization step of my process. The materials are iirst dried by passing through driers 84 and 85 which are arranged in parallel and are provided with valves 88, 81, 88 and 89, whereby either one of driers 84 or 85 may be cut out of the system for reiilling Without shutting down the operaton. Th dried materials are then passed through line 98 and optionally through heater or heat interchanger 9| into the catalytic polymerization chamber 92 which is ordinarily provided with internal cooling means 93. I have illustrated a chamber containing a mass of catalyst with internal cooling means but I may also use other arrangements and, for example, I may position my catalyst in tubes which are surrounded by the cooling medium and I may also maintain my catalyst in molten liquid form without the use of any support or carrier and bubble my g-ases therethrough.

As catalyst I prefer to use substances of the aluminum halide stable double salt type wherein the other metallic halide may be sodium chloride, lithium chloride, sodium bromide, cuprous chloride, antimony bromide, mercuric bromide, etc., the compound sodium chloroaluminate being a typical example of this type of catalyst. The catalysts of this type are characterized by the fact that they exert an active polymerizing action on the heavier gaseous olenes, i. e., propylene and butylene, but have a relatively slight polymerizing action on ethylene. 'I'he particular catalyst used forms no part of my invention except that I prefer to use a catalyst of the above described type having a selective action on the heavier gaseous oleflns.

The catalyst reaction chamber 92 is preferably operated under pressures of 200 to 1000 lbs. per sq. in. and at temperatures of 200-550 F. and the gas mixture is charged thereto at a rate equal to 40G-8000 cubic feet of free gas (i. e., measured at atmospheric pressure and 60 F.) per cubic ft. of free catalyst volume per hour.

Reaction products removed from chamber 92 pass through valve 94 and line 95 into fractionator 96 which is'provided with suitable bottom heating means 91 and top cooling means 98 and is operated under pressures of 50 to 350 pounds per sq. inch. I may operate fractionator 98 so as to remove all liquid hydrocarbons comprising gasoline and heavier through the bottom outlet valve 99, removing all unconverted gases, including butane and lighter, through the top outlet valve |88. In this case the gasoline and gas oil formed by the catalytic polymerization, together with any heavy or tarry materials, are passed through line |8| back to the previously described cracking system and are either introduced through valve |82 into bubble tower I4 or through valve |83 into evaporator 23. The latter arrangement will be. used if the products contain any substantial quantity of materials heavier than gas oil. Pumping means may be provided in line 8| if necessary. By this means the gasoline produced by the catalytic polymerization is fractionated and stabilized in the aforedescribed fractionating steps of the cracking system and is recovered and removed from the system through the line 15 in admixture with the gasoline formed by cracking. Furthermore, any materials heavier than gasoline which are formed by the catalytic polymerization are ultimately returned to the cracking furnace 31 for conversion into additional amounts of gasoline.

The unconverted gases removed from fractionator 96 through valve |88 may be removed from the system through valve |84 for suitable outside treatment or disposal but may also be passed through valve |85 in line |88 to a fractionating system which is operated in conjunction with the previously described oil cracking system for the rectification of the gases and light virgin naphtha flashed from the crude oil in section |2 of the flash tower. 'I'his fractionating system may be described as follows:

Vapors from section 2 of the crude flash tower, being removed through line |1a, are cooled by condenser |81 and passed to separator |88 from the top of which, through line |89, dry gas consisting essentially of methane is removed. The light virgin naphtha is removed from the bottom of the separator |88 by pump |89a and is passed through line ||8 to stabilizer which is provided with suitable bottom heating means ||2 and top cooling means ||3. From the bottom of stabilizer the stabilized light virgin naphtha from the crude is withdrawn through outlet valve H4, and gas consisting predominatingly of propane and ethane, together (under certain conditions) with some butane, is removed through line ||5 and may be removed from the system for suitable outside treatment or disposal through valve |16 but is preferably passed through valve ||1 in line H8 to fractionator |9 which is provided with suitable bottom heating means |28 and top cooling means |2| whereby butane is removed as a liquid bottom product through outlet |22 and propane, together with any ethane present, is removed as a gaseous top product and may be eliminated from the system through valve |23 for suitable outside disposal or may be passed through valve |24 in line |25 to the gas cracking furnace |26 which will be later described in more detail.

Returning to the fractionator 96, the unconverted and essentially saturated gases removed through outlet |88 may be passed through line |86 into the just described light virgin naphtha stabilizing system, being passed either through valve |21 and line |28 to the inlet of pump I89a or being passed through valve |29 and pump |38 directly into the fractionator I9. By this means all saturated gases, i. e., ethane, propane and butane, are recovered in admixture with similar gases present in the crude oil and which have been obtained in the stabilization of the light virgin naphtha.

Instead of passing gases and vapors from fractionator 96 through outlet |00 as above described, I may pass them through line |3| and valve |32 into fractionator |33 which is provided with suitable bottom heating means |34 and with suitable top cooling means |35 whereby butane may be withdrawn as a. liquid condensate through outlet |36 and removed from the system for suitable outside disposal, and propane together with any ethane may be removed through line |31 and may be eliminated from the system for suitable outside disposal through valve |38 or may be passed through valve |39 to line |06 for treatment as previously described in stabilizer and/or fractionator ||9 or may be passed directly to gas cracking furnace |26 through valve |39a in line |39b.

I may also operate fractionators 96 and |33 under such conditions that only gas oil is obtained as a bottom product from fractionator 96, gasoline vapors passing overhead and being recovered as a bottom product from fractionator |33.- 'I'he gas oil from fractionator 96 will be returned through line |0| to evaporator 23 or bubble tower |4. In this case the top product from fractionator |33 will contain all excess butane and lighter gases and I may pass this overhead product through valve |40 in line |4| into fractionator |42 which is provided with sultable bottom heating means |43 and to-p cooling means |44 whereby excess butane is removed as a bottom product and withdrawn from the system for suitable disposal through outlet valve |45 in line |46, while propane together with any ethane is removed as vapor through outlet |41 and may be eliminated from the system for suitable disposal through valve |48 or may be passed through line |49 and valve |50 to line |06 to stabilizerf and/or fractionator ||9 or to gas cracking furnace |26 directly, as previously de scribed. v

As was stated in connection with the description of fractionator 18, the gas fraction removed therefrom through line 8|, containing ethylene as its predominant olefin constituent, is passed to the intake of pump |5| whereby it is passed to the high pressure polymerization furnace |52. Therein it is subjected to non-catalytic polymerization at pressures of 1000 to 3000 pounds per square inch and temperatures of 850 to 1100 F. I have illustrated the furnace |52 as being provided with a soaking coil type of flow but instead of this, or in addition `to this, I may utilize an unheated reaction drum (not shown) following the furnace. Products from the high pressure polymerization furnace |52 are passed through water-cooled condenser |53 or equivalent cooling means following which the pressure is reduced by valve |54 and the liquid products and unconverted gases are passed to separator |55 wherein the pressure and temperature are such that a dry gas containing predominatingly methane and hydrogen is removed from the top through offtake |56, liquid products and condensed heavy gases being removed through bottom offtake |51. These liquid products and unconverd gases may be passed through valve |58 and line |59 to line |0| whereby they are returned to the evaporator 23 or bubble tower I4 of the cracking system. Ordinarily, however, I prefer to fractionate unconverted gases separately and to return only the liquid polymerization products to the cracking system. To this end I pass products from the bottom of separator |55 through line |60 and valve |6| to fractionator |62 which is provided with suitable bottom heating means |63 and top cooling means |64-, gasoline, gas oil and any heavier constituents of the high pressure polymerization products being withdrawn through line |65 and valve |66 to line |0| whereby they are returned to evaporator 23 or bubble tower |4 and the gasoline is recovered in admixture with the cracked gasoline, while the liquid polymerization products heavier than gasoline are subjected to cracking to obtain additional amounts of gasoline.

Gaseous products removed from the top of fractionator |62 through line |61 will consist mainly of ethane, propane, and butane, together with small amounts of the corresponding oleflns which have not been polymerized in furnace |52. I may eliminate these gases from the system through valve |68 or I may pass them through line |69 and valve |69a to the inlet of gas cracking furnace |26 which will be later described in more detail. I may also pass them through line |10, valve |1| and valve |12 in line |13 to line |14 whereby they are passed to the inlet of pump 83 which charges the catalytic polymerization reaction chamber and whereby any propylene or butylene contained therein will be catalytically polymerlzed while other gaseous constituents will be given suitable ultimate disposition by the previously described fractionating apparatus following polymerization chamber 92, i. e., will be eliminated from the system or will be cracked in gas cracking furnace |26 to generate additional olefin gases.

I may also pass gases from fractionator |62 through line |10, valve |1| and valve |15 (using pumping'means, not shown, if necessary) to fractionator |16 which is provided with suitable bottorn heating means |11 and suitable top cooling means |18 and whereby these gases will be separated and ethane, together with any ethylene, will be withdrawn from the top through line |19 while any propane and butane, together with any propylene and butylene, will be withdrawn as a liquid condensate through offtake (or I may eliminate ethane-propane through line |19 and Withdraw butane through line |80), and optionally eliminated from the system through valve |8|, but preferably passed through valve |82 to line |14 whereby it is returned to the catalytic polymerization chamber for treatment as previously described.

The ethane fraction removed from fractionator |16 through line |19 may be eliminated from the system through valve |83 but preferably is passed either through valve |84 whereby it is recycled to the high pressure polymerization furnace |52 or through valve |85 in line |86 whereby it is passed to line |69 and thereby to the gas cracking furnace |26 later described in detail. If I recycle part of this fraction through valve |84 `to the high pressure polymerization furnace |52 it will be necessary to pass another part thereof through valve |85 to the gas cracking furnace |26, or to eliminate a part thereof from the system through Valve |83, in order to prevent a gradual building up of ethane in the feed to the high pressure polymerization furnace |52. The balance between these possibilities will be determined mainly by the ethylene content of the unconverted gas from high pressure polymerization furnace |52 and the higher this ethylene content the larger the proportion of gas which I will ordinarily recycle to the furnace |52.

Although I do not limit myself thereto, as an added element of my process I prefer to operate my process in conjunction with a gas cracking step, reference having previously been made to gas cracking furnace 26 wherein this step is carried out. 'Ihis furnace is operated at pressures of 0-100 pounds per square inch above atmospheric and temperatures of 1350-1650 F. The gas charged to the furnace is predominatingly saturated in character and ordinarily I prefer not t'o introduce any gas streams containing a large or predominating proportion of methane since methane does not yield readily to cracking to form olenic hydrocarbons. Furthermore, I prefer not to charge any substantial proportion of butane to furnace 26 since the amount of butane produced in my system can ordinarily be blended in toto in the finished gasoline and there is therefore no advantage in subjecting it to cracking to form oleiines for repolymerization to gasoline. I therefore prefer to charge gas cracking furnace 26 with a mixture consisting predominatingly of ethane and propane which may be obtained from fractionator ||9 (by line |25),

rfrom fractionator |62 (via oiftake |61, valve |69a and line |69), from fractionator |33 (via outlet |31, valve |39, valve |05, line |06, valve |29, valve |39a, and through line |3912), from fractionator |42 (via outlet |41, line |49, valve |50, line |06, valve |06, valve |39a, and through line |3917) or from fractionator |16 (via offtake |19, valve |85 and lines |86 and |69). It will also be seen that, as previously described, the gas from fractionator ||9 may contain saturated unconverted gases from catalytic polymerization chamber 92 which are eliminated in fractionators 96, |33 and/or |42 and are conveyed to fractionator ||9 through line |06 (or via line |06, valve |21, line |28, separator |08 and stabilizer By these various arrangements I preferably charge gas cracking furnace |26 with all ethane and propane produced in my system, including that originally present in the crude oil and also the larger amounts formed by cracking section of my process and recovered from the products of the catalytic polymerization chamber 92 and/or the high pressure polymerization furnace |52.

Following the gas cracking furnace |26 suitable cooling means |81 are used which may comprise a direct oil spray cooler and/or suitable indirect cooling means, following which the cooled gases are introduced into tar separator |88 wherein tar is removed from the system through offtake |89 and gases containing a large proportion of gaseous olenes, predominatingly ethylene, are removed through line |90 for treatment by high pressure polymerization in furnace |52. I prefer to separate inert gases, such as methane and hydrogen, from this gas prior to introduction into furnace |52 and may do so by any convenient means but preferably I introduce said gases by pump |9| and line |92 into separator 68 wherein it joins gases and liquid products from the cracking system whereby its methane and hydrogen content are eliminated in conjunction with methane and hydrogen from the cracking system, and the ethylene formed in gas cracking furnace 26 thus ultimately passes to high pressure polymerization furnace |52 via line 8| in conjunction with similar ethylenic gases produced in the cracking system.

I have previously stated that I prefer to operate stabilizer 12 so that overhead gases, consisting predominantly of ethane, ethylene, propane and propylene, are passed into fractionator 18 and are therein separated into an ethylenic gaseous fraction which is charged through line 8| to high pressure polymerization` furnace |52,

and a propylenlc liquid fraction which is withdrawn through line 82 and charged to the catalytic polymerization chamber 92. By closing valve 11 immediately prior to fractionator 18 and opening valve |93 in line |94 I may. however, pass all gases from stabilizer 12 and line 16 directly to line 82 entering the catalytic polymerization system. In this arrangement the higher gaseous olenes are polymerized to liquids in the catalytic polymerization chamber 92 while the ethylene present in the feed gas is converted to a minor degree only. In this case I may operate the fractionating system following the catalytic reaction chamber 92, as exemplified by fractionators 96, |33 and |42, so as to separatek an ethylenic gas fraction which is passed directly to the inlet of pump |5| supplying the high pressure polymerization furnace 52, either from fractionator |83 through offtake |31 and valved line |95, or from fractionator |42 through offtake |41, and valve |96.

As previously stated, I prefer to operate my improved process using the catalytic polymerization c step, the high pressure non-catalytic polymerization step and the gas cracking step, all in conjunction with an oil cracking step as previously described. I may, however, operate only the catalytic polymerization step or the catalytic polymerization step plus the high pressure noncatalytic polymerization step, in conjunction with my oil cracking step as will be evident from the foregoing description.

`The primary advantages of my improved process are that I obtain increased yield of gasoline of improved quality from the crude oil; that I eliminate butylene from this gasoline whereby I may increase its butane content and therebyv improve its volatility'and starting characteristics without increasing its vapor-locking tendency in internal combustion engine system; that my gasoline has improved antiknock value; and

that I accomplish these results with a minimum of apparatus and a maximum of economy of fuel and other operating costs.

It will be understood that I am not limited in my invention as above described except as set forth in the claims as follows:

I claim:

1. In a combined oil cracking and gas. polymerization process, the steps comprising heating a flowing stream of hydrocarbon oil during its flow through an elongated passageway to a cracking temperature while maintained under a super-atmospheric pressure, maintaining the oil stream at said temperature and under said pressure until the desired conversion into motor fuel products and normally gaseous hydrocarbons is effected, thereafter passing the stream of reaction products to a separating zone wherein heavy hydrocarbon products are separated in liquid form and lighter hydrocarbon products are separated in vapor form, collecting said heavy hydrocarbon products and recycling a part of themv polymerizing said admixture of normally gaseous' hydrocarbons containing olefins, separating motor fuel and higher boiling polymer products from lighter products of the effluent from the polymerization step and returning said motor fuel and higher boiling polymer products to said separating zone, and recovering from said fractionating zone said motor fuel polymer in admixture with motor fuel products formed in the oil cracking step.

2. A process in accordance with claim l wherein the catalytic polymerization of the admixture of normally gaseous hydrocarbons containing olefins is effected at temperatures of 250 to 550 F. and pressures of 200 to 1,000 pounds per square inch.

3. In a combined oil cracking and gas polymerization process, the steps comprising heating a flowing stream of hydrocarbon oil during its flow through an elongated passageway to a cracking temperature while maintained under a superatmospheric pressure, maintaining the oil stream at said temperature and under said pressure until the desired conversion into motor fuel products and normally gaseous hydrocarbons is effected, thereafter passing the stream of reaction products to a separating zone wherein heavy hydrocarbon products are separated in liquid form and lighter hydrocarbon products are separated in vapor form, collecting said heavy hydrocarbon products and recycling a part of them for further cracking, separately withdrawing vapors from said separating zone and fractionating them in a fractionating zone to separate therefrom as separate fractions liquid motor fuel products containing substantially no butane and an admixture of normally gaseous hydrocarbons containing olens and butane, catalytically polymerizing said admixture of normally gaseous hydrocarbons to form polymer products boiling within the gasoline range, separating gasoline and higher boiling polymer products as one fraction and liquid butane as a second fraction from the products of the polymerization step, returning said gasoline and higher boiling polymer products to said separating zone, recovering from said fractionating zone said gasoline polymer in admixture with the motor fuel products containing substantially no butane, and blending butane with said admixture of gasoline polymers and motor fuel products to form a motor fuel product of desired volatility.

4. In a combined oil cracking and gas polymerization process, the steps comprising heating a flowing stream of hydrocarbon oil during its flow through an elongated passageway to a cracking temperature while maintained under a super-atmospheric pressure, maintaining the oil stream at said temperature and under said pressure until the desired conversion into gasoline-like products and normally gaseous hydrocarbons is effected, thereafter passing the stream of reaction products to a separating zone wherein heavy hydrocarbon products are separated in liquid form and lighter hydrocarbon products are separated in vapor form, collecting said heavy hydrocarbon products and recycling a part of them for further cracking, separately withdrawing vapors from said separating zone and fractionating them in a fractionating zone to separate therefrom as separate fractions the desired motor fuel products and an admixture of normally gaseous hydrocarbons containing oleflns, subjecting said normally gaseous hydrocarbons containing oleflns to catalytic polymerization to form liquid polymer products including motor fuel constituents, separating unconverted gases from the products of the catalytic polymerization step, subjecting said unconverted gases to thermal polymerization at elevated temperatures and high super-atmospheric pressures to form liquid polymer products/ including motor fuel constituents, returning liquid motor fuel products and heavier hydrocarbon products from'both polymerization steps to said separating zone, and recoveringfrom said fractionating zone motor fuel polymer products from both of said polymerization steps in admixture with the motor fuel products produced in the oil cracking step.

5. In a combined oil cracking and gas polymerization process, the steps comprising heating a flowing stream of hydrocarbon oil during its flow through an elongated passageway to a cracking temperature while maintained under a superatmospheric pressure, maintaining the oil stream at said temperature and under said pressure until the desired conversion into motor fuel products and normally gaseous hydrocarbons is effected, thereafter passing' the stream of reaction products to a separating zone wherein vaporous constituents are separated from unvaporized constituents, fractionating said vaporized constituents in a fractionating zone to separate `therefrom insufficiently cracked products as reflux condensate, returning at least a part of said reflux condensate for further cracking, separately withdrawing vaporous constituents remaining after said fractionation and passing them to a second fractionating zone to separate therefrom as separate fractions liquid motor fuel products and an admixture of normally gaseous hydrocarbons containing olefins, catalytically po-lymerizing said admixture of normally gaseous hydrocarbons containing olefins, separating motor fuel and higher boiling polymer products from lighter products of the eflluent from the polymerization step and returning. said motor fuel and higher boiling polymer products to the first fractionating zone and recovering from the second ,fractionating zone said motor fuel polymer in admixture with motor fuel products formed in the oil cracking step.

6. In a combined oil cracking and gas polymerization process, the steps comprising heating a flowing stream of hydrocarbon oil during its flow through an elongated passageway to a cracking temperature while maintained under superatmospheric pressure, maintaining the oil stream at said temperature and under said pressure until the desired conversion to motor fuel products and normally gaseous hydrocarbons is effected, thereafter passing the stream of reaction products to a separating zone wherein vaporous constituents are separated from unvaporized constituents, fractionating said vaporized constituents in a fractionating zone to separate therefrom insuiciently cracked products as reflux condensate, returning at least a part of said reflux condensate for further cracking, separately withdrawing vaporous constituents remaining after said fractionation and passing them to a second fractionating zone to separate therefrom as separate fractions liquid motor fuel products and an admixture of normally gaseous olefin-containing hydrocarbons substantially free from hydrogen and methane, catalytcally polymerizing the admixture of normally gaseous olefin-containing hydrocarbons substantially free from hydrogen and methane, separating motor fuel and higher boiling polymer products from lighter products of the effluent from the polymerization step and returning said motor fuel and higher boiling polymer products to the first fractionating zone and recovering from the second fractionating zone said motor fuel polymer products in admixture with motor fuel products lformed inthe oil cracking step.

7. In a combined oll cracking and gas polymerization process, the steps comprising heating a flowing stream of hydrocarbon oil during its flow through an elongated passageway to a cracking temperature While maintained under superatmospheric pressure, maintaining the oil stream at said temperature and under said pressure until the desired conversion to motor fuel products and normally gaseous hydrocarbons is effected, thereafter passing the stream of reaction products to a separating' zone wherein vaporous constituents are separated from unvaporized constituents, fractionating said vaporized constituents in a fractionating zone to separate therefrom insufficiently cracked products as reflux condensate, returning at least a part of said reflux condensate for further cracking, separately withdrawing vaporous constituents remaining after said fractionation and passing them to a second fractionating zone to separate therefrom as separate fractions liquid motor fuel products and an admixture of normally gaseous olefin-containing hydrocarbons substantially free from hydrogen and methane, catalytically polymerizing said admixture of normally gaseous olefin-containing hydrocarbons substantially free from hydrogen and methane while maintained under an elevated pressure and at a temperature within the range of 20G-550 F., separating motor fuel and higher boiling polymer products from lighter products of the effluent from the ploymerization step and returning said motor fuel and higher boiling poly'- mer products to the first fractionating zone and recovering from the second fractionating zone said motor fuel polymer products in admixture with motor fuel products formed in the oil cracking step.

8. In a combined oil cracking and gas polymerization process, the steps comprising heating a flowing stream of hydrocarbon oil during its flow through an elongated passageway to' a cracking temperature while maintained under superatmospheric pressure, maintaining the oil stream at said temperature and under said pressure until the desired conversion to motor fuel products and normally gaseous hydrocarbons is effected, thereafter passing the stream of reaction products to a separating zone wherein vaporous constituents are separated from unvaporized constituents, fractionating said vaporized constituents in a fractionating zone to separate therefrom insufficiently cracked products as reflux condensate, returning at least a part of said reflux condensate for further cracking, separately withdrawing vaporous constituents remaining lafter said fractionation and passing them to a second fractionating zone to separate therefrom as separate fractions liquid motor fuel products and an admixture of normally gaseous hydrocarbons comprising mostly C3 and C4 hydrocarbons, catalytically polymerizing said admixture of normally gaseous hydrocarbons comprising mostly C: and C4 hydrocarbons, separating motor fuel and higher boiling polymer products from lighter products of the effluent from the polymerization step and returning said motor fuel and higher boiling polymer products to the first fractionating zone and recovering from the second fractionating zone said motor fuel polymer products in admixture with motor fuel products formed in the oil cracking step.

9. In a combined oil cracking and gas polymerization process, the steps comprising heating a flowing stream of hydrocarbon oil during its flow through an elongated passageway to a cracking temperature while maintained under a superatmospheric pressure, maintaining the oil stream at said temperature and under said pressure until the desired conversion into moto-r fuel products and normally gaseous hydrocarbons is effected, thereafter passing the stream of reaction products to a separating zone wherein heavy hydrocarbon products are separated in liquid form and lighter hydrocarbon products are separated in vapor form, collecting said heavy hydrocarbon products and recycling a part of them for further cracking, separately withdrawing vapors from said separating zone and fractionating them in a fractionating zone to separate therefrom as separate fractions liquid motor fuel products and an admixture of normally gaseous olefin-containing hydrocarbons substantially free from hydrogen and methane, catalytically polymerizing said admixture of normally gaseous hydrocarbons substantially free from hydrogen and methane, separating motor fuel and higher boiling polymer products from lighter products of the effluent from the polymerization step and returning said motor fuel and higher boiling polymer products to said separating zone, and recovering from said fractionating zone said motor fuel polymer in admixture with motor fuel products formed in the oil cracking step.

10. In a combined oil cracking and gas polymerization process, the steps comprising heatingY a flowing stream of hydrocarbon oil during its flow through an elongated passageway to a cracking temperature while maintained under superatmospheric pressure, maintaining the oil stream at said temperature and under said pressure until the desired conversion to motor fuel productsand normally gaseous hydrocarbons is effected, thereafter passing the stream of reaction products to a separating zone wherein vaporous constituents are separated from unvaporized constituents, fractionating said vaporized constituents in a fractionating zone to separate therefrom insulciently cracked products as reflux condensate, returning at least a part of said reflux condensate for further cracking, separately withdrawing vaporous constituents remaining after said fractionation and passing them to a second fractionating Zone to separate therefrom as separate fractions liquid motor fuel products and an admixture of normally gaseous olefin-containing hydrocarbons substantially free from hydrogen and methane, catalytically polymerizing said admixture or normally gaseous olefin-containing hydrocarbons substantially free from hydrogen and methane, separating Amotor fuel and higher boiling polymer products from unconverted gases of the effluent from the catalytic polymerization step, subjecting said unconverted gases to thermal polymerization at elevated temperatures and high super-atmospheric pressures to form. motor fuel and higher boiling polymer products, returning motor fuel and higher boiling polymer products from both polymerization steps to the first fractionating zone, and recovering from the second fractionating zone said motor fuel polymer products in admixture with motor fuel products formed in the oil cracking step.

11. In a combined oil cracking and gas polymerization process, the steps comprising heating a flowing stream of hydrocarbon oil during its flow through an elongated passageway to a cracking temperature while maintained under superatmospheric pressure, maintaining the oil stream at said temperature and under said pressure until the desired conversion to motor fuel products and normally gaseous hydrocarbons is eilected, thereafter passing the stream of reaction products to a separating zone wherein vaporous constituents are separated from unvaporized constituents, fractionating said vaporized constituents in a fractionating zone to separate therefrom insumciently cracked products as reflux condensate, returning at least a part of said reflux condensate for further cracking, separately withdrawing vaporous constituents remaining after said fractionation and passing them to a second fractionating zone to separate as separate fractions liquid motor fuel products and an admixture of normally gaseous olefin-containing hydrocarbons substantially free from hydrogen and methane, catalytically polymerizing said admixture'of normally gaseous olefin-containing hydrocarbons substantially free from hydrogen and methane, separating motor fuel and higher boiling polymer products from unreacted gases of the eilluent from th'e polymerization step, returning said motor fuel and higher boiling polymer products to the first fractionating zone, recovering from the second fractionating zone said motor fuel polymer in admixture with motor fuel products formed in the oil cracking step, thermally converting said unreacted gases into olefinic gases, and passing said oleflnic gases to the second fractionating vzone wherein they are recovered as part of the admixture of normally gaseous olefin-'containing hydrocarbons substantially free from hydrogen and methane. l D

12. In a combined oil cracking and gas polymerization process, th'e steps comprising heating a flowing stream of hydrocarbonoil during its ilow through an elongated passageway to a cracking temperature while maintained under a superatmospheric pressure, maintaining the oil stream at said temperature and under said pressure until the desired conversion into motor fuel products and normally gaseous hydrocarbons is effected, thereafter passing the stream of reaction products to a separating zone wherein heavy hydrocarbon products are separated in liquid form and lighter hydrocarbon products are separated in vapor form, collecting said heavy hydrocarbon products and recycling a part of them for further cracking, separately withdrawing vapors from said separating zone and fractionating them in a fractionating zone to separate therefrom as separate fractions liquid motor fuel products and an admixture of normally gaseous olefin-containing hydrocarbons substantially free from hydrogen and methane, catalytically polymerizing said admixture of normally gaseous olefin-containing hydrocarbons substantially free from hydrogen and methane.' separating motor fuel and higher boiling polymer products from unreacted gases of the eflluent from the polymerization step and returning said motor fuel and higher boiling polymer products to said separating zone, recovering from said fractionating zone said motor fuel polymer in admixture with motor fuel products formed in the oil cracking step, thermally converting said unreacted gases into oleflnic gases,

and passing said oleilnic gases to said fractionat- A ing zone wherein they are recovered as a part of the admixture of normally gaseous olefin-containing hydrocarbons substantially free from hydrogen and methane.

13. In a combined oil cracking and gas polymerization process, the steps comprising heating a flowing stream of hydrocarbon oil during its flow through an elongated passageway to a cracking temperature while maintained under superatmospheric pressure, maintaining the oil stream at said temperature and under said pressure until the desired conversion to motor fuel products and normally' gaseous hydrocarbons is effected, thereafter passing the stream of reaction products to a separating zone wherein vaporous constituents are separated from unvaporized constituents, fractionating said vaporized constituents in a fractionating zone to separate therefrom insumciently cracked products as reflux condensate, returning at least a part of said reflux condensate for further cracking, separately withdrawing vaporous constituents remaining after said fractionation and passing them to a second fractionating zone to separate therefrom as separate fractions liquid motor fuel products and an admixture of normally gaseous olefin-containing hydrocarbons substantially free from hydrogen and methane, catalytically polymerizing said admixture of normally gaseous olefin-containing hydrocarbons substantially free from hydrogen and methane, separating motor fuel and higher boiling polymer products from unreacted gases of the eilluent from the polymerization step, returning said motor fuel and higher boiling polymer products to the ilrst fractionating zone, recovering from the second fractionating zone said motor fuel polymer in admixture with motor fuel products formed in the oil cracking step, thermally converting said unreacted gases into olefinic hydrocarbons, removing inert gases from said olenic gases and polymerizing these olefinic gases along with said admixture of normally gaseous olefin-containing hydrocarbons substantially free from hydrogen and methane.

ROBERT F. RUTHRUFF. 

